Hearing aid battery packaging

ABSTRACT

A battery package includes a card and multiple battery packs. Each battery pack includes a cover attached to a portion of the card, and a tray positioned between the portion of the card and the cover. The cover includes an opening and a door. The door is movable between an open position and a closed position. The tray includes multiple receptacles. Each battery pack further includes multiple batteries and multiple tabs. Each battery is positioned within one of the receptacles. Each tab is removably attached to one of the batteries. The tray is rotatable relative to the portion of the card and the cover to selectively align one of the receptacles with the opening in a battery removal position. With the door in the open position, the tab attached to the battery in the receptacle in the battery removal position is accessible through the opening.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/943,591, filed Apr. 2, 2018, which is a continuation of U.S.application Ser. No. 15/694,490, filed Sep. 1, 2017, which is acontinuation-in-part of U.S. application Ser. No. 15/148,951, filed May6, 2016, which claims the benefit of U.S. Application No. 62/158,941,filed May 8, 2015, all of which are incorporated herein by reference intheir entireties.

BACKGROUND

The present invention relates to packaging for button cell batteries,and particularly to packaging for hearing aid batteries.

Button cell batteries are frequently used in hearing aids, and, are thussmall in size having a diameter which can be less than half the width ofa finger. Moreover, the small battery size results in a limited powersupply, and requires replacement in a hearing aid at regular intervals.In order to accommodate frequent replacement of these batteries, thebatteries are typically sold in packages containing a plurality of thebatteries.

One known battery package includes a plastic cover rotatably mounted toa card. The cover includes receptacles which open to the card. Eachreceptacle receives a single battery which is accessed through a cutoutformed in the card. The cover is rotated to align a battery with thecutout, and the battery is popped out of the receptacle through thecutout. However, because the battery is accessed through the cutout inthe card, it can be difficult to grasp the battery, instead, the usermay turn the package over and rely on gravity to remove the battery fromthe package. Further, because cutout is on the back of the card, thecutout is obscured from a user looking at the front of the packaging.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to a battery package. Thebattery package includes a card and multiple battery packs. Each batterypack includes a cover attached to the portion of the card, and a traypositioned between the portion of the card and the cover. The coverincludes a body having a front portion, an outer circumferential flange,and an annular transition portion extending between the front portionand the flange. The body includes an opening and a door and the door ismovable between an open position to provide access to the opening and aclosed position in which the door closes the opening. The tray includesmultiple receptacles arranged symmetrically about a central post. Thefront surface of the central post is spaced apart from the interiorsurface of the front portion of the cover by a distance. Each batterypack also includes multiple batteries, each battery positioned withinone of the receptacles, and multiple tabs, each tab removably attachedto one of the batteries with each tab positioned between the cover andthe battery to which the tab is attached. The tray is rotatable relativeto the portion of the card and the cover about an axis of rotation thatextends through the central post to selectively align one of thereceptacles with the opening in a battery removal position. With thedoor in the open position, the tab attached to the battery in thereceptacle in the battery removal position is accessible through theopening from the front of the cover and the peripheral edge of thecover.

Another embodiment of the invention relates to a battery package. Thebattery package includes a card, a cover, a tray, multiple batteries,and multiple tabs. The card includes a first portion and a secondportion separated by a perforation configured to detach the firstportion from the second portion. The first portion includes an openingconfigured to receive a display hanger. The cover is attached to thesecond portion card. The cover includes an opening and a door, whereinthe door is movable between an open position to provide access to theopening and a closed position in which the door closes the opening. Thetray is positioned between the card and the cover. The tray includesmultiple receptacles. Each battery is positioned within one of thereceptacles. Each tab is removably attached to one of the batteries,wherein each tab is positioned between the cover and the battery towhich the tab is attached. The tray is rotatable relative to the secondportion of the card and the cover about an axis of rotation toselectively align one of the receptacles with the opening in a batteryremoval position. With the door in the open position, the tab attachedto the battery in the receptacle in the battery removal position isaccessible through the opening.

Another embodiment of the invention relates to a battery package. Thebattery package includes a card, a cover attached to the card, and atray positioned between the card and the cover. The cover includes anopening and a door. The door is movable between an open position toprovide access to the opening and a closed position in which the doorcloses the opening. The tray includes multiple receptacles. The batterypackage further includes multiple batteries and multiple tabs. Eachbattery is positioned within one of the receptacles. Each tab isremovably attached to one of the batteries. Each tab is positionedbetween the cover and the battery the tab is attached to. Each tabincludes a free end extending past the battery to which the tab isattached. The tray is rotatable relative to the card and the cover toselectively align one of the receptacles with the opening in a batteryremoval position. The free end of the tab attached to the battery in thereceptacle in the battery removal position is depressed by the doortoward the card when the door is in the closed position. The free end ofthe tab attached to the battery in the receptacle in the battery removalposition moves away from the card when the door moves from the closedposition to the open position.

Another embodiment of the invention relates to a battery package. Thebattery package includes a card, a cover attached to the card, and atray positioned between the card and the cover. The cover includes anopening and a door. The door is movable between an open position toprovide access to the opening and a closed position in which the doorcloses the opening. The tray includes multiple receptacles. The batterypackage further includes multiple batteries and multiple tabs. Eachbattery is positioned within one of the receptacles. Each tab isremovably attached to one of the batteries. Each tab is positionedbetween the cover and the battery to which the tab is attached. The trayis rotatable relative to the card and the cover to selectively align oneof the receptacles with the opening in a battery removal position. Withthe door in the open position, the tab attached to the battery in thereceptacle in the battery removal position is accessible through theopening which provides an arc of access of at least 90 degrees.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a battery pack, according to an exemplaryembodiment.

FIG. 2 is a side view of the battery pack of FIG. 1.

FIG. 3 is a front perspective view of the battery pack of FIG. 1.

FIG. 4 is a front exploded perspective view of the battery pack of FIG.1.

FIG. 5 is a rear perspective view of the battery pack of FIG. 1.

FIG. 6 is a rear exploded perspective view of the battery pack of FIG.1.

FIG. 7 is a front perspective view of the battery pack of FIG. 1illustrating a door opened to allow access to a battery.

FIG. 8 is a front perspective view of the battery pack of FIG. 1illustrating a portion of a backer card removed.

FIG. 9 is a front view of a removable tab, according to an exemplaryembodiment.

FIG. 10 is a front view of a removable tab, according to an exemplaryembodiment.

FIG. 11 is a front view of a removable tab, according to an exemplaryembodiment.

FIG. 12 is a front view of a battery pack, according to an exemplaryembodiment.

FIG. 13 is a front view of a battery pack, according to an exemplaryembodiment.

FIG. 14 is a side view of the battery pack of FIG. 12.

FIG. 15 is an exploded view of the battery pack of FIG. 12.

FIG. 16 is a front view of a card of the battery pack of FIG. 12.

FIG. 17 is a front view of a card of a battery pack, according to anexemplary embodiment.

FIG. 18 is an exploded view of a battery pack, according to an exemplaryembodiment.

FIG. 19 is a front view of the battery pack of FIG. 12 including atamper evidence adhesive strip.

FIG. 20 is a front perspective view of a battery package, according toan exemplary embodiment.

FIG. 21 is a front view of the battery package of FIG. 20.

FIG. 22 is an exploded view of the battery package of FIG. 20.

FIG. 23 is a front view of a card of the battery package of FIG. 20.

FIG. 24 is a front perspective view of a cover of the battery package ofFIG. 20.

FIG. 25 is a section view of the battery package of FIG. 20, along line25-25 in FIG. 21.

FIG. 26 is a front view of the cover of FIG. 24.

FIG. 27 is a section view of the cover of FIG. 24, along line 27-27 ofFIG. 26.

FIG. 28 is a section view of the cover of FIG. 24, along line 28-28 ofFIG. 26.

FIG. 29 is a section view of the cover of FIG. 24, along line 29-29 ofFIG. 26.

FIG. 30 is a detail view of the section view of the cover of FIG. 24.

FIG. 31 is a detail view of the section view of the cover of FIG. 24according to an alternative embodiment.

FIG. 32 is a front perspective view of a battery package, according toan exemplary embodiment.

DETAILED DESCRIPTION

Referring to FIGS. 1-8, a battery pack or package 10 is illustratedaccording to an exemplary embodiment. The battery pack 10 includes acard 12, a transparent cover or blister 14 that is fixed to the card 12,and a tray or dial 16 that is positioned between the card 12 and thecover 14 and is rotatable relative to the card 12 and the cover 14. Oneor more button cell batteries 18 are received in the tray 16, and arecontained beneath the cover 14. The tray 16 and the cover 14 areconfigured with a relatively low profile, allowing the battery 18 to beeasily removed from the battery pack 10 for use.

The card 12 is preferably formed from a flexible material. In oneembodiment, the card 12 is a die-cut paperboard card which can carryidentifying indicia and advertising thereon. In other embodiments, thecard 12 may be formed from another material, such as a polymer material,or combination of materials. The card 12 may be formed from multiplelayers, such as a first or front layer 20 and a second or rear layer 22.The layers may have different properties (e.g., shape, profile,thickness, material, etc.). For example, the front layer 20 may beconfigured to carry the identifying indicia and advertising while therear layer 22 may be configured to provide structural rigidity to thecard 12. A display hanger opening or slot 24 formed through both thefront layer 20 and the rear layer 22 of the card 12 can be provided tofacilitate hanging the battery pack 10 on a display hanger for displayto potential users. A circular opening 26 is formed in the front layer20 and the rear layer 22 of the card 12. The circular opening 26 isconfigured to receive a portion of the tray 16 such that the tray 16 isrotatably coupled to the card 12. As shown in FIGS. 4 and 6, a multitudeof indexing apertures 28 are provided in the front layer 20 and mayoptionally extend through the rear layer 22. The apertures 28 receivefeatures of the tray 16 to provide indexing positions for the tray 16related to the number of batteries 18 contained within the batterypackage 10. The indexing apertures 28 are equidistantly spaced about thecircular opening 26. A cutout 30 in the front layer 20 and the rearlayer 22 along a bottom edge 32 of the card 12 provides clearance for adoor 43 of the cover 14.

The cover 14 is a dome-shaped body with a relatively flat front portion40, an outer circumferential flange 42, and a convex, annular transitionportion 44 extending between the front portion 40 and the flange 42. Thefront portion 40 is substantially parallel to the card 12. The frontportion 40 may include a central recess or indent 41. The flange 42 isaffixed to the card 12, forming an internal volume between the cover 14and the card 12 in which the tray 16 is disposed. According to anexemplary embodiment, the flange 42 is coupled to the front layer 20 ofthe card 12, such as with an adhesive, heating sealing, etc. In anotherembodiment, the flange 42 may be coupled to the rear layer 22 of thecard 12 and captured between the front layer 20 and the rear layer 22.In other embodiments, the cover 14 may be coupled to the card 12 byother means, such as with anchors or protrusions that engage the card12, mechanical fasteners, or any other fastening means that preventsrotation of the cover 14 relative to the card 12.

The cover 14 is preferably formed at least partially from a clearplastic which allows potential users to view the batteries 18 in thebattery pack 10. According to one exemplary embodiment, the entire cover14 is formed (e.g., by thermoforming) from a transparent plasticmaterial. In other embodiments, only a portion of the cover may betransparent. For example, the cover 14 may be formed from multiplecomponents, only some of which are transparent plastic or portions ofthe cover 14 may be made opaque (e.g., with a paint, dye, label, etc.).

The interior volume between the cover 14 and the card 12, as well as thetray 16 and batteries 18 contained therein, may be accessed by a userthrough an opening 45 in the cover 14 with an integrally formed door 43(e.g., flap, hatch, etc.). The cover 14 is positioned on the card 12such that a portion of the flange 42 is coincident with the bottom edge32 of the card 12. The door 43 is a wedge-shaped body with a narrow endcoupled to the cover 14 by a living hinge 46 and a relatively widedistal end 48. The distal end 48 is aligned with the cutout 30 along thebottom edge 32 of the card 12. The door 43 includes a curved convexportion 49 that corresponds to the transition portion 44 of the cover 14and a flat flange or latch 51 that corresponds to the flange 42 of thecover 14 and includes the distal end 48 of the door 43. The edges 47 ofthe door 43 may be initially fixed to the cover 14 along a breakableseam or by tack points which join the edges 47 to the cover 14 to holdthe door 43 in a closed position (e.g., preventing access to thebatteries 18 through the opening 45). In order to access the batteries18, the seam or tack points are severed to allow the door 43 to pivotabout the living hinge 46 to the open position (see FIG. 7). Althoughtack points are disclosed to initially hold the door 43 in the closedposition, other methods can be used, such as an adhesive strip coveringthe door 43.

Once the seam or tack points are severed or the door 43 is otherwisefree to pivot about the living hinge 46, the door 43 may be held in theclosed position through other means. According to an exemplaryembodiment, in the closed position, the flange 51 of the door 43 isaligned with the cutout 30 and is held in place by tabs 34 extendinginwardly into the cutout 30 from the cutout edges so that the flange 51is located below the tabs 34. When moving the door 43 to the openposition, the tabs 34 and/or the door 43 deform to allow the flange 51of the door 43 to move out of the cutout 30 and the door 43 to pivotabout the living hinge 46, away from the cover 14. Similarly, whenmoving the door 43 to the closed position, the tabs 34 and/or the door43 deform to allow the flange 51 of the door 43 to pass into the cutout30. The door 43 may be configured such that its default position is theopen position, the closed position, or a partially opened position.

The tray 16 includes multiple battery receptacles 50 that open towardthe front of the battery pack 10 (e.g., toward the cover 14 and awayfrom the card 12). The receptacles 50 are spaced equidistantly from arotational axis 52, and are individually sized to receive one of thedisc shaped batteries 18. The receptacle 50 includes a first portion,shown as a cylindrical portion 54, in which the battery 18 is received,and a second portion, shown as a wedge-shaped portion 56, extending awayfrom the cylindrical portion 54 toward the peripheral edge 55 of thetray 16. The receptacle 50 is open in two directions—toward the frontsurface 64 of the tray 16 and toward the peripheral edge 55 of the tray16. The two directions of access provide an arc of access of 90°. Thisimproves user access to the receptacle 50 and the battery 18 it containsas compared to known battery packages that only provide access to abattery from a single direction (e.g., from the back side of a tray).When the tray 16 is positioned between the card 12 and the cover 14, thecylindrical portions 54 of the receptacles 50 are generally aligned withthe front portion 40 of the cover 14 while the wedge-shaped portions 56are generally aligned with the transition portion 44 of the cover 14.

Although each receptacle 50 is shown as being configured to receive asingle disc shaped battery 18, the receptacles can be formed to receivemore than one battery and batteries which are not disc shaped withoutdeparting from the scope of the invention. The tray 16 is illustrated asincluding eight receptacles 50 so that the battery pack 10 can holdeight batteries 18. In other embodiments, the tray 16 includes more orfewer receptacles 50 and the battery pack 10 can hold more or fewerbatteries 18.

The tray 16 is rotatably coupled to the card 12. The tray 16 includes acentral boss 60 extending in a rearward direction from a rear surface 62of the tray 16 and away from a curved front surface 64 surrounding thereceptacles 50. The central boss 60 is coaxial with the rotational axis52 of the tray 16. The central boss 60 extends through the circularopening 26 of the card 12. The central boss 60 provides a cylindricalbearing surface 63 that contacts the edges of the card 12 defining thecircular opening 26 to locate the tray 16 relative to the card 12 andthe cover 14. One or more protrusions 66 extend rearward from the rearsurface 62 and are configured to engage the corresponding indexingapertures 28 in the card 12. The indexing aperture 28 are eachpreferably spaced radially about the axis 52 such that rotation of thetray 16 is indexed to align the battery receptacles 50 with the opening45 in the cover 14 as the tray 16 rotates about the axis 52. Although aplurality of indexing apertures 28 formed in the card 12 which areengageable with the protrusions 66 extending from the rear surface 62 ofthe tray 16 is disclosed, other methods for indexing the rotation of thetray 16 can be used without departing from the scope of the invention,such as providing a plurality of protrusions which engage a singleaperture, forming the apertures in the tray 16 and the protrusions onthe card 12, and the like. Advantageously, the indexing also preventsinadvertent rotation of the tray 16, which may align a battery 18 withthe opening 45 in the cover 14 when the door 43 is not in the closedposition, resulting in a battery 18 falling out of the pack 10.

The central boss 60 of the tray 16 includes one or more grip features68. According to an exemplary embodiment, the grip features are recessesformed in the central boss and separated by a raised wall 69 integrallyformed with the central boss 60. The grip features 68 provide structuresthat may be grasped by the user, allowing the user to rotate the tray 16about the rotational axis 52 to align a battery 18 with the opening 45in the cover 14. According to an exemplary embodiment, the raised wall69 is curved to provide an ergonomic structure and to provide a visualcue for the rotation of the tray 16. In other embodiments, the gripfeatures 68 may be otherwise shaped. For example, the grip features maybe formed by radial walls, a surface texture, a star-shaped structure,or any other suitable body that provides a structure that may be graspedby the user.

According to an exemplary embodiment, a depression 58 is formed on thefront side of the tray 16. The depression 58 is centered on therotational axis 52 and is surrounded by the receptacles 50. Thedepression 58 has a diameter and a depth such that it is configured toreceive the central indent 41 of the cover when the tray 16 ispositioned between the card 12 and the cover 14. With the tray 16sandwiched between the card 12 and the cover 14, the tray 16 contactsthe edges of the card 12 defining the circular opening 26 with thecylindrical bearing surface 63 of the central boss 60 and contacts thefront face of the card 12 with the rear surface 62. The central boss 60locates the tray 16 relative to the cover 14 such that the tray 16 onlycontacts the central indent 41 of the cover 14 (e.g., in the depression58) and the peripheral edges 55 of the tray 16 and the front surface 64are recessed from the transition portion 44 of the cover 14. Thefriction between the cover 14 and the tray 16 is therefore minimized.The tray 16 may be formed from a plastic material that provides a lowfriction surface on which the tray 16 rotates.

The batteries 18 can be any battery known in the art, such as a zinc airbattery suitable for use as a hearing aid battery. The battery pack 10may be configured for batteries of a wide variety of sizes (e.g.,diameters, thicknesses, etc.). While the battery pack 10 is shown tocontain eight button cell batteries 18, in other embodiments, thebattery pack 10 may be configured to contain any number of batteries.

According to an exemplary embodiment, a self-adhesive tab 70 is fixed toeach battery 18 to prevent premature discharge of the zinc air batteryby covering openings in the battery 18 which allows atmospheric oxygento enter the battery 18. Advantageously, the tab 70 simplifies handlingand positioning the battery 18 when inserting the battery 18 in abattery operated device. Preferably, a free end 72 of each tab 70 isreceived in the second, wedge-shaped portions 56 of the receptacles 50.The tab 70 is preferably formed from a non-porous, relatively stiffmaterial. For example, the tab 70 may be formed from a plastic film, ametal foil, a foil-backed film, or any other suitable material. The tabs70 are presented on the front side of the battery pack 10 and arevisible through the transparent cover 14. Each tab 70 includes the freeend 72 and a fixed end 73 that is fixed to the battery 18. As shown inFIG. 1, the tab 70 extends for a length 75 between the two ends 72 and73. The tab 70 may be colored to provide a visual cue (e.g., tradedress, number of batteries 18, etc.) to a potential buyer. The tab 70may be colored to match the color of the card 12. In some embodiments,the tabs 70 are embossed or textured to make the tab 70 easier to graspby the user. In some embodiments, as shown in FIG. 1, a grasping portion79 of the tab 70 is textured. The grasping portion 79 is at least aportion of the part of the tab 70 that extends past the battery 18 tothe free end 72.

Referring to FIGS. 9-11, the size and shape of the tab 70 may vary. Thetab 70 includes the grasping portion 79 and a battery portion 81. Thebattery portion 81 is intended to line up with the center of the battery18 when the battery portion 81 is attached to a battery 18. The width 75of the grasping portion 79 (measured across the widest point) ispreferably 9 millimeters or longer. The width of tabs used withconventional battery packs is 8.25 millimeters or less. The increasedwidth 75 of the tabs 70 provides a larger surface area for the graspingportion 79 making the tab easier for a user to grasp than the taps usedwith conventional battery packs.

When the battery 18 and the attached tab 70 are received in thereceptacle 50 of the battery tray 16, the tab 70 extends outward suchthat the free end 72 of the tab 70 extends toward the peripheral edge 55of the tray 16. In some embodiments, the free end 72 of the tab 70 mayextend beyond the front surface 64 of the tray 16. The free end 72 ispressed downward by the transition portion 44 of the cover 14. Thebattery 18 and the tab 70 are recessed with respect to the front surface64 such that, when a particular receptacle 50 is not aligned with theopening 45 in the cover 14, the tab 70 does not become lodged in the gapbetween the front surface 64 of the tray 16 and the cover 14 when thetray 16 rotates about the axis 52.

Referring to FIG. 7, when a receptacle 50 in which the tab 70 andattached battery 18 are received is aligned with the opening 45 in thecover 14 and the door 43 is opened, the stiffness of the materialforming the tab 70 causes the free end 72 of the tab to spring forward,away from the tray 16. The tab 70 “sits up” and is therefore moreaccessible for a user to grasp the tab 70 and remove the attachedbattery 18. The clearance between the tab 70 and the tray 16 facilitatesthe removal of the tab 70 and attached battery 18 from the tray 16 by auser, making it easier for the user to grasp the free end 72 of the tab70 and remove the battery 18 from the receptacle 50. The domed shape ofthe cover 14 and the tray 16 housed beneath the cover 14 provides for aconvenient removal of the battery 18 by the user. Because the doorextends from the front portion 40 of the cover 14 through the slopedtransition portion 44 and to the circumferential flange 42, the opening45 allows access to the battery 18 and the tab 70 not only from thefront surface of the pack 10 but also laterally, from the bottomperipheral edge of the pack 10.

In use, with reference to FIGS. 1-7, the tray 16 is rotated about theaxis of rotation 52 until a battery 18 and tab 70 contained in areceptacle 50 of the tray 16 is aligned with the door 43 (e.g., throughthe interaction between the one or more protrusions 66 and thecorresponding indexing apertures 28). A user engages the door 43 using afinger, and frees the door 43 such that it may move relative to thecover about the living hinge 46. Initially, this may involve severingtack points or other fastening means used to initially fix the edges ofthe door 43 to the cover 14. The user then removes the battery 18 fromthe receptacle 50 by grasping the tab 70. The pack 10 is closed bypivoting the door 43 about the hinge 46 to the closed position in whichthe distal end 48 of the door passes into the cutout 30 and is retainedby the tabs 34. The tabs 34 hold the door 43 in the closed positionuntil another battery 18 is desired, and the user repeats the process.The user is able to grasp the peripheral or outer edge of the pack 10with one hand while twisting the central boss 60 of the tray via thegrip features 68 with a second hand from the back side of the batterypack 10. This arrangement allows the user to view the batteries 18throughout the process of advancing a battery 18 into the removalposition.

Referring to FIG. 8, according to an exemplary embodiment, a portion ofthe card 12 may be removable. For example, a top portion 74 of the card12 may be detachable from a bottom portion 76 of the card 12 coupled tothe cover 14 and the tray 16 along a curved perforation 78. Asillustrated, the curved perforation 78 is a portion of a circle. Inother embodiments it may be otherwise shaped (e.g., linear). The curvedperforation 78 allows for a compact sized removable portion of thebattery pack 10 by matching the shape of the card 12 following removalof the portion 74 with the shape of the cover 14. By removing the topportion 74 of the card 12, the remainder of the battery pack 10 providesa more discrete, compact package that may be more easily transported,such as in a pocket, handbag, suitcase, or other container. When storedin such a manner, the smooth, low profile shape of the cover 14 reducesthe likelihood that the bottom portion 76 of the battery pack 10 willbecome snagged or caught on another object or open inadvertently. Asshown in FIG. 1, the perforation 78 has a smaller diameter than thecover 14 so that the perforation 78 is located behind the flange 42 ofthe cover 14. The perforation 78 is located between the outer edge ofthe cover 14 and the axis of rotation 52. This ensures that the smoothouter edge of the cover 14 is located outside of the edge formed by theperforation 78 after the top portion 74 of the card 12 is removed toreduce the likelihood that the bottom portion 76 of battery pack 10 willbecome snagged or caught on another object or open inadvertently.

Referring to FIGS. 12-16 illustrate a battery pack 110 according to anexemplary embodiments. Many features of the battery pack 110 are similarto those of the battery pack 10 and will not be discussed in detailbelow. The battery pack 110 includes a card 112, a transparent cover orblister 114 that is fixed to the card 112, and a tray or dial 116 thatis positioned between the card 112 and the cover 114 and is rotatablerelative to the card 112 and the cover 114 about an axis of rotation152. One or more button cell batteries 118 are received in the tray 116,and are contained beneath the cover 114.

As shown in FIG. 12, the door 143 of the cover 114 is located 45 degreescounterclockwise from the position of the door 43 of the cover 14 shownin FIG. 1. A center line 125 dividing the door 143 into halves ispositioned at an interior angle α of 45 degrees relative to a plane 127including the axis 152 and the midpoint 129 of the width 131 of thehanger slot 124. As shown in FIG. 13, the door 143 of the cover 114 islocated 45 degrees clockwise from the position of the door 43 of thecover 114 shown in FIG. 1. The center line 125 dividing the door 143into halves is positioned at an interior angle β of 45 degrees relativeto a plane 127 including the axis 152 and the midpoint 129 of the width131 of the hanger slot 124. In a coordinate system where the axis 152 isthe z-axis and the y-axis is found in the plane 127, the door 143 ispreferably located within a range of 135 degrees (FIG. 12) to 225degrees (FIG. 13) relative to the z-axis (axis 152). The door 43 asshown in FIG. 1 is located at 180 degrees relative to the z-axis (axis52). Positioning the door 143 at these locations increases the radialdepth of the flange or latch 151 as compared to the latch 51 of the door43. Also, the card 112 and the cover 114 are formed to include twostraight edges 133 and 135 arranged perpendicularly to one another.These straight edges 133 and 135 help to increase the strength of thebattery pack 110 when packed in a box or other container by providing anincreased and flat contact area between the battery pack 110 and thesurface of the container. In the embodiments of FIGS. 1, 12, and 13, theaxis 52 or 152 is located between the door 43 or 143 and the removabletop portion 74 or 174 of the card 12 or 112.

As shown in FIG. 14, the cover 114 is a dome-shaped body with arelatively flat front portion 140, an outer circumferential flange 142,and an annular transition portion 144 extending between the frontportion 140 and the flange 142. The front portion 140 is substantiallyparallel to the card 112. The flange 142 is attached to the card 112,forming an internal volume between the cover 114 and the card 112 inwhich the tray 116 is disposed. The transition portion 140 includes astep, protrusion, or ledge 119 that extends around the circumference ofthe cover 114. The ledge 119 helps to guide the tabs 170 as the tray 116is rotated. The bottom surface of the ledge 119 engages the uppersurface of the tabs 170 so that the tabs 170 ride along the ledge 119 asthe tray 116 is rotated. The contact between the bottom surface of theledge 119 and the upper surface of the tabs 170 as the tray rotateshelps to smooth the travel of the tabs 170 and limits jostling of thebatteries 118 that can dislodge a battery 118 from a receptacle 150.

As shown in FIG. 15, the body of the battery pack 110 (i.e., thecomponents other than the batteries 118 and the tabs 170) consists ofthree pieces—a polymer card 112, the cover 114, and the tray 116. Thetray 116 includes multiple battery receptacles 150 including acylindrical portion 154 and a wedge-shaped portion 156. The outer orperipheral edge or circumference 155 of the tray 116 is recessed by arecess or cutout 161 at each receptacle 150. The cutout 161 results inthe radius of the tray 116 (relative to the axis of rotation 152) ateach receptacle 150 being less than the radius of the tray 116 betweenadjacent receptacles 150. The cutout 161 provides access to a user'sfinger to the tab 170. The bottom portion 176 of the card 112 includes arecess or cutout 177 in the outer edge 165 of the card 112 that isaligned with the door 143 of the cover 114 at the battery removalposition. As shown in FIG. 16, the cutout 177 has a width 183 and adepth 185. Preferably, the width 183 is greater than 15 millimeters. Thewidth of doors providing access to conventional battery packs may beonly about 9 millimeters. The increased width 183 provides easier accessto a finger (including the thumb) of a user, making it easier to removea battery from the battery pack 110. Also, the inclusion of the cutout161 in the tray 116 and the cutout 177 in the card 112 makes thereceptacle 150 aligned with the door 143 open for access by the userwhen the door 143 is open in three directions—from above through thespace occupied by the door 143 when closed, from the side through thespace occupied by the door 143 when closed and through the cutout 161 inthe peripheral edge 155 in the tray 116, and from below through thecutout 177 in the card 112 and through the cutout 161 in the tray 116.The three directions of access provide an arc of access from above tobelow of greater than 90°. This improves user access to the receptacle150 aligned with the door 143 and the battery 118 it contains ascompared to known battery packages that only provide access to a batteryfrom a single direction (e.g., from the back side of a tray). Thepolymer card 112 provides locking tabs 134 that do not lose shape orotherwise become damaged due to repeated latching and unlatching of thedoor 143. The indexing apertures 128 are formed as notches in theopening 126 through the card 112 for receiving a portion of the tray 116to allow the tray 116 to rotate about the axis 152 relative to the card112.

Referring to FIG. 17, a card 212 for a battery pack is illustratedaccording to an exemplary embodiment. The card 212 includes two portions276A and 276B that are removable from the portion 274. Curvedperforations 278 separate the portions 276A and 276B from the portion274. The card 212 thereby provides two battery packs.

Referring to FIG. 18, a battery pack 310 is illustrated according to anexemplary embodiment. The body of the battery pack 310 (i.e., thecomponents other than the batteries 318 and the tabs 370) consists offour pieces—a card 312 having a polymer layer 313 and a paper layer 317,the cover 314, and the tray 316. The polymer layer 313 providesadditional strength to the paperboard layer 317, particularly for thelocking tabs 334 and the index apertures 328. As illustrated, theindexing apertures 328 are formed as notches in the opening 326. In someembodiments, the polymer layer 313 includes a top portion 374 and abottom portion 376 that can be separated from one another. In otherembodiments, the polymer layer 313 only includes the bottom portion 376and thereby provides the additional strength for the locking tabs 334and the index apertures 328 while eliminating the material needed forthe top portion 374. The polymer layer 313 is attached to the paperboardlayer 317 (e.g., by ultrasound welding, heat welding, adhesive, etc.).

Referring to FIG. 19, a tamper evidence adhesive strip 115 is attachedacross the door 143 to the portions of the cover 114 adjacent the door143. The strip 115 extends across the door 143 and is attached to thedoor 143 and the portions of the cover 114 adjacent the door 143. Whenthe door 143 is opened for the first time, the strip 115 breaks toindicate that the door 143 has been opened. In a retail environment, abroken strip 115 indicates tampering with the battery pack 110 byshowing the retailer that someone has opened the door 143 without payingfor the battery pack 110 (e.g., in an attempt to steal one or morebatteries 118 from the battery pack 110).

As shown in FIGS. 20-31, a battery package 410 is illustrated accordingto an exemplary embodiment. The battery package 410 includes a card 412,a blister or cover 414, and a dial or tray 416. Many features of thebattery package 410 are similar to those of the battery packs 10,110,and 310 and will not be discussed in detail below. Similar features areidentified with the same names used above.

Referring to FIG. 23, the card 412 is made from a polymer. The polymermay be of various types of including Polyethylene terephthalate glycol(i.e., PETG), polyvinyl chloride (i.e., PVC), or other plastics. Thecover 414 is also made from a polymer. The polymer may be of varioustypes of including Polyethylene terephthalate glycol (i.e., PETG),polyvinyl chloride (i.e., PVC), or other plastics. In a preferredembodiment, the card 412 and the cover 414 are both made from PETG,which improves the bond between the card 412 and the cover 414 when theyare secured to one another (e.g., by thermal or ultrasonic bonding).

The card 412 includes a recess 477 formed in the outer edge 462 of thecard 412. The recess 477 is aligned with the door 443 and the opening426 at the battery removal position. The recess 477 is defined in partby a pair of locking tabs 434 and 435, each of which is located adjacentto one of a pair of card cutouts 436 and 437. The recess 477 has arecess width 478 measured at the closest points between the two lockingtabs 434 and 435. The pair of card cutouts 436 and 437 are separatedfrom each other by a cutout width 480 measured at the furthest pointsbetween the two card cutouts 436 and 437. The cutout width 480 isgreater than the recess width 478.

Referring to FIG. 22, the tray 416 includes multiple battery receptacles450. The receptacles 450 surround a central post or pillar 453. Asshown, eight receptacles 450 are arranged symmetrically around the post453. In other embodiments, more or fewer receptacles 450 are provided(e.g., four receptacles, six receptacles, ten receptacles, twelvereceptacles). The axis of rotation 452 extends through the post 453. Asshown, the axis of rotation 452 is perpendicular to the front surface455 of the post 453.

Referring to FIG. 24, the cover 414 is a dome-shaped body 415 with afront portion 440, an outer circumferential flange 442, and an annulartransition portion 444 extending between the front portion 440 and theflange 442. As illustrated, the front portion 440 is substantially flatand is substantially parallel to the card 412. In other embodiments, thefront portion 440 may be curved.

Referring to FIG. 25, the front portion 440 is spaced apart from thefront surface 455 of the post 453 of the tray 416 by a distance 457. Thedistance 457 provides a gap or space between the front portion 440 ofthe cover 414 and the central post 453 of the tray 416. This gap allowsthe tray 416 to travel slightly within the volume defined by the cover414 and the card 412 while still allowing for easy rotation of the tray416. The gap also allows for imperfections in manufacturing of the tray416. For example, if one or more portions of the tray 416 is warped orotherwise curved (i.e., not flat), the protrusions of the tray 416 maynot engage consistently with the indexing apertures 428 formed in thecard 412. By providing the gap, any slight imperfections in the tray 416or the cover 414 do not affect operation and rotation of the tray 416.In a preferred embodiment, the distance between the front surface 455 ofthe post 453 of the tray 416 and the interior surface of the frontportion 440 of the cover 414 is 0.015 inch (0.381 millimeter).

Referring to FIG. 26, the body 415 has an opening 445 defined in part bytwo spaced apart opening sides 447 and 449 with a first portion 454 ofthe body 415 adjacent the first opening side 447 and a second portion456 of the body 415 adjacent the second opening side 449. The door 443is pivotally attached to the body 415 by a hinge 446 so that the hinge446 connects the two opening sides 447 and 449. The opening 445 and thedoor 443 are aligned with the recess 477 in the card 412 at the batteryremoval position.

The door 443 also includes a main portion or base 458, a neck 460, and alatch 451 located at the distal end of the door 443 from the hinge 446with the neck 460 connecting the base 458 to the latch 451. The neck 460is narrower in width than the base 458 and the latch 451. The maximumbase width 459 is greater than the maximum neck width 461 and themaximum latch width 463 is also greater than the maximum neck width 461.The maximum latch width 463 is also greater than the recess width 478 ofthe recess 477 of the card 412.

Referring to FIG. 21, the door 443 is movable between an open positionto provide access to the opening 445 and a closed position in which thedoor 443 closes the opening 445 and the latch 451 engages both of thelocking tabs 434 and 435 of the card 412 to secure the door 443 in theclosed position. The latch 451 includes two end portions 465 and 467located opposite from each other so that with the door 443 in the closedposition each end portion 465 or 467 of the latch 451 is located beneathone of the two locking tabs 434 and 435 of the card 412 to secure thedoor 443 in the closed position. With the door 443 in the closedposition, each end portion 465 or 467 of the latch overlaps a portion ofone of the locking tabs 434 and 435. The overlapping regions found atthe end portions 465 and 467 of the latch 451 help to ensure a securelatch of the door 443 to the card 412 thereby securing the door 443 inthe closed position.

Referring to FIG. 27, the latch 451 has an outer portion 466 and a ridge468 extending away from the outer portion 466 with the rear surface 472of the ridge 468 spaced apart from the rear surface 473 of the outerportion 466 to define a grasping recess 474. The ridge 468 also definesa wall or ledge 476 located on the rear side of the latch 451 adjacentthe grasping recess 474 configured to assist a user in grasping thelatch. The grasping recess 474 and the ledge 476 are each configured toassist a user in grasping the latch 451. When the user reaches a fingerunderneath the door 443, the grasping recess 474 provides room for theuser to curl her fingertip under the door and the ledge 476 provides acontact point for the user's fingertip and/or fingernail to gainpurchase on the door 443. Improving the ability of the user isparticularly important when the battery package 410 contains hearing aidbatteries which are frequently used by the elderly. The elderly may havedifficulty manipulating or clearing seeing the door 443 and the recess474 and ledge 476 help with grasping the latch 451 and also providetactile feedback to the user that her finger is in the proper positionon the latch to open the door 443.

Referring to FIG. 26, a pair of door cutouts 469 and 471 separate thelatch 451 from the base 458 of the door 443. Referring to FIG. 21, withthe door 443 in the closed position, the first card cutout 436 isaligned with the first door cutout 469 and the second card cutout 437 isaligned with the second door cutout 471. During assembly of the batterypackaging 410, the aligned cutouts function as through holes thatreceive pins to position and properly align the card 412 and the cover414 relative to one another.

Referring to FIG. 28, the door 433 includes a surface 482 recessed fromthe adjacent portions of the door 443 with the surface 482 is recessedtoward the tray 416. The recessed surface 482 helps provide rigidity andstrength to the door 443. The door 443 also includes two gussets orridges 484 extending radially along the door 443 in the directionbetween the hinge 446 and the latch 451. The ridges 484 also help toprovide rigidity and strength the door 443. In some embodiments, therecessed surface 482 and the ridges 484 are omitted. In otherembodiments, more or fewer ridges 484 are included. Some embodimentsinclude a recessed surface 482, but no ridges 484 and other embodimentsinclude one or more ridges 484, but no recessed surface 482.

Referring to FIGS. 26 and 29-31, the cover 414 also includes atransition protrusion 490 extending from the rear side of the body 415toward the card 412. The transition protrusion 490 is located in thefirst portion 454 of the body 415. A second transition protrusion 492also extends from the rear side of the body 415 toward the card 412. Thetransition protrusion 492 is located in the second portion 456 of thebody 415.

Both of the transition protrusions 490 and 492 are arranged similarly soonly the transition protrusion 490 will be described in detail. Thetransition protrusion 490 includes a leading surface 494 and a trailingsurface 496 located closer to the battery removal position than theleading surface 494. The transition protrusions 490 and 492 are curved,angled, or otherwise profiled from the bottom surface of the cover 414toward the card 412.

Referring to FIG. 30, the leading surface 494 and the trailing surface496 are curved. As illustrated, the radius of curvature 498 of theleading surface 494 is less than the radius of curvature 500 of thetrailing surface 496. In other embodiments, the radius of curvature 498is the same as the radius of curvature 500. In other embodiments, theradius of curvature 498 is greater than the radius of curvature 500.Referring to FIG. 31, the leading surface 494 is angled at a leadingangle 502 relative to the front portion 440 of the cover 414 and thetrailing surface 496 is angled at a trailing angle 504 relative to thefront portion 440. The leading angle 502 and the trailing angle 504 areexterior angles measured on the rear side of the cover 414. Asillustrated, the leading angle 502 is greater than the trailing angle504. In other embodiments, the leading angle 502 and the trailing angle504 are the same. In other embodiments, the leading angle 502 is lessthan the trailing angle 504.

When the tray 416 is rotated relative to the card 412 and the cover 414to selectively align one of the receptacles 450 with the opening 443 atthe battery removal position, the battery 418 and the tab 470 of thebattery 418 approaching the battery removal position contact and travelalong one of the two transition protrusions 490 and 492. The transitionprotrusion 490 or 492 guides the battery 418 and its associated tab 470toward one of the opening side 447 or 449 and the opening 445. Thisguidance helps to prevent the seat the battery 418 in its receptacle 450and reduces the likelihood of the battery 418 and/or the tab 470 fromcatching or hanging up on one of the opening sides 447 and 449 or theedges of the door 443 as the battery 418 moves to the battery removalposition.

Referring to FIG. 32, the battery package 410 is illustrated accordingto an exemplary embodiment that provides two battery packs from the mainbody of the card 412 in a manner similar to the card 212 describedabove.

It should be noted that the term “exemplary” as used herein to describevarious embodiments is intended to indicate that such embodiments arepossible examples, representations, and/or illustrations of possibleembodiments (and such term is not intended to connote that suchembodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two members directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., movable,removable, or releasable). Such joining may be achieved with the twomembers or the two members and any additional intermediate members beingintegrally formed as a single unitary body with one another or with thetwo members or the two members and any additional intermediate membersbeing attached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,”“above,” “below,” “front,” “rear,” “back,” “axial,” “radial,” etc.) areused to describe the orientation of various elements as illustrated inthe Figures.

It is important to note that the construction and arrangement of thebattery package as shown in the various exemplary embodiments areillustrative only. Although only a few embodiments have been describedin detail in this disclosure, those skilled in the art who review thisdisclosure will readily appreciate that many modifications are possible(e.g., variations in sizes, dimensions, structures, shapes andproportions of the various elements, values of parameters, mountingarrangements, use of materials, colors, orientations, etc.) withoutmaterially departing from the novel teachings and advantages of thesubject matter described herein. For example, elements shown asintegrally formed may be constructed of multiple parts or elements, theposition of elements may be reversed or otherwise varied, and the natureor number of discrete elements or positions may be altered or varied.The order or sequence of any process or method of steps may be varied orre-sequenced according to alternative embodiments. Other substitutions,modifications, changes and omissions may also be made in the design,operating conditions and arrangement of the various exemplaryembodiments without departing from the scope of the present invention.

What is claimed is:
 1. A battery package, comprising: a card; and aplurality of battery packs, each battery pack comprising: a coverattached to a portion the card, the cover including an opening and adoor wherein the door is movable between an open position to provideaccess to the opening and a closed position in which the door closes theopening; a tray positioned between the portion of the card and thecover, the tray including a plurality of receptacles; a plurality ofbatteries, each battery positioned within one of the plurality ofreceptacles; and a plurality of tabs, each tab removably attached to oneof the batteries, wherein each tab is positioned between the cover andthe battery to which the tab is attached; wherein the tray is rotatablerelative to the card and the cover to selectively align one of thereceptacles with the opening in a battery removal position; and whereinwith the door in the open position, the tab attached to the battery inthe receptacle in the battery removal position is accessible through theopening via an arc of access of at least 90 degrees.
 2. The batterypackage of claim 1, wherein for each battery pack, each receptacleincludes a first portion and a second portion extending away from thefirst portion toward the peripheral edge of the tray so that the arc ofaccess is 90 degrees.
 3. The battery package of claim 1, wherein foreach battery pack, each portion the card includes a card recess in theouter edge of the portion of the card that is aligned with the door ofthe cover at the battery removal position; and wherein for each batterypack, each receptacle includes a first portion, a second portionextending away from the first portion toward the peripheral edge of thetray, and a receptacle recess at the peripheral edge of the tray so thatthe arc of access is greater than 90 degrees.
 4. The battery package ofclaim 1, wherein for each battery pack, the plurality of receptacles areformed in a front side of the tray and the tray includes a gripextending away from a rear side of the tray; and wherein the cardincludes an opening that the grip of the tray extends through so that auser may grasp the grip to rotate the tray.
 5. The battery package ofclaim 1, wherein the card comprises a polymer.
 6. The battery package ofclaim 5, wherein for each battery pack, the tray and the portion of thecard include a plurality of indexing features for indexing rotation ofthe tray to a plurality of predetermined positions.
 7. A batterypackage, comprising: a card; and a plurality of battery packs, eachbattery pack comprising: a cover attached to a portion of the card, thecover including a body having a front portion, an outer circumferentialflange, and an annular transition portion extending between the frontportion and the flange, the body includes an opening and a door, whereinthe door is movable between an open position to provide access to theopening and a closed position in which the door closes the opening; atray positioned between the portion of the card and the cover, the trayincluding a plurality of receptacles arranged symmetrically about acentral post, wherein the front surface of the central post is spacedapart from the interior surface of the front portion of the cover by adistance; a plurality of batteries, each battery positioned within oneof the plurality of receptacles; and a plurality of tabs, each tabremovably attached to one of the batteries, wherein each tab ispositioned between the cover and the battery to which the tab isattached; wherein the tray is rotatable relative to the portion of thecard and the cover about an axis of rotation that extends through thecentral post to selectively align one of the receptacles with theopening in a battery removal position; and wherein with the door in theopen position, the tab attached to the battery in the receptacle in thebattery removal position is accessible through the opening from thefront of the cover and the peripheral edge of the cover.
 8. The batterypackage of claim 7, wherein for each battery pack, the distance betweenthe front surface of the central post and the front surface of the coveris 0.015 inch.
 9. The battery package of claim 7, wherein for eachbattery pack, the plurality of receptacles are formed in a front side ofthe tray and the tray includes a grip extending away from a rear side ofthe tray; and wherein for each battery pack, the portion of the cardincludes an opening that the grip of the tray extends through so that auser may grasp the grip to rotate the tray.
 10. The battery package ofclaim 7, wherein the card comprises a polymer.
 11. The battery packageof claim 10, wherein for each battery pack, the tray and the portion ofthe card include a plurality of indexing features for indexing rotationof the tray to a plurality of predetermined positions.
 12. The batterypackage of claim 10, wherein for each battery pack, the cover comprisesthe polymer.
 13. The battery package of claim 12, wherein the polymer isPETG.
 14. The battery package of claim 7, wherein for each battery pack,the cover comprises a polymer.
 15. A battery package, comprising: acard; and a plurality of battery packs, each batter pack comprising: acover attached to a portion of the card, the cover including; a bodyhaving an opening defined in part by two spaced apart opening sides,wherein a first portion of the body is adjacent the first opening sideand a second portion of the body is adjacent the second opening side, adoor pivotally attached to the body by a hinge so that the hingeconnects the two opening sides, a first transition protrusion extendingfrom the rear side of the body toward the card, the first transitionprotrusion located in the first portion of the body, and a secondtransition protrusion extending from the rear side of the body towardthe card, the second transition protrusion located in the second portionof the body, wherein the door is movable between an open position toprovide access to the opening and a closed position in which the doorcloses the opening; a tray positioned between the portion of the cardand the cover, the tray including a plurality of receptacles; aplurality of batteries, each battery positioned within one of theplurality of receptacles; and a plurality of tabs, each tab removablyattached to one of the batteries, wherein each tab is positioned betweenthe cover and the battery to which the tab is attached; wherein the trayis rotatable relative to the portion of the card and the cover about anaxis of rotation that extends through the central post to selectivelyalign one of the receptacles with the opening in a battery removalposition so that as the tray rotates, the battery and the tab of thebattery approaching the battery removal position contact and travelalong one of the two transition protrusions; and wherein with the doorin the open position, the tab attached to the battery in the receptaclein the battery removal position is accessible through the opening fromthe front of the cover and the peripheral edge of the cover.
 16. Thebattery package of claim 15, wherein for each of the battery packs, eachof the transition protrusions includes a leading surface and a trailingsurface located closer to the battery removal position than the leadingsurface.
 17. The battery package of claim 16, wherein for each of thebattery packs, the leading surfaces and the trailing surfaces arecurved.
 18. The battery package of claim 17, wherein for each of thebattery packs, the radius of curvature of the leading surface is lessthan the radius of curvature of the trailing surface.
 19. The batterypackage of claim 16, wherein for each of the battery packs, the body ofthe cover includes a front portion, each leading surface is angled at aleading angle relative to the front portion, and wherein each trailingsurface is angled at a trailing angle relative to the front portion. 20.The battery package of claim 19, wherein for each battery pack, theleading angle is greater than the trailing angle.